I have finally encounter a problem that has stumped me. My 2004 rsvr factory has seen around 18.5K of road miles and is running a 16x18 brembo billet clutch master, MPL billet slave cylinder, and a #40 oil jet. The set up has functioned very well for well over 8K miles. I recently switched out the clutch lever for the brembo folding version. I then took the bike on a 300+ mile ride and all seemed well. A day after the ride the clutch felt like it was disengaging really far out in the lever travel. I suspected a worn clutch so I pulled the clutch cover and checked everything out.
The clutch frictions and steels looked great to my surprise. The stack hight was about 47mm. I then checked the springs and found they were worn to 1mm below the minimum value at 43mm. I went ahead and installed a Barnett clutch kit. I used the first factory steel to being with. I put everything back together and ensured the clutch was bleed properly and discovered that the clutch would not disengage fully. In fact, once the bike was warm it was impossible to shift into any gear. At this point I thought the Barnett was the source of the new issues so I replaced the frictions and steels with my existing stock units. I then found that the bike behaved exactly the same. At this point I was puzzled.
Since my MPL billet slave has about 14K on it I thought maybe it's seal had given up. I swapped the MPL slave out for the stock unit along with a new seal. I made sure the system was bleed properly and to my surprise the bike still exhibited the same symptoms now with a slightly harder clutch pull.
Next, I thought maybe the folding lever was the incorrect part but after a bit of research I discovered there is only one folding lever offered by brembo for the billet units. Next, I thought I might have inadvertently screwed up some adjustment in the master cylinder during the lever swap. I have recently heard that the billet racing master cylinders do not have a free play adjustment so that can't be it. I was still stumped so I switch out he original clutch frictions and steels with everything that came in the Barnett kit. The stack hight is currently 46.6mm. The clutch still behaves exactly the same. At this point I am stumped. Is it possible the master cylinder has shot craps on me? I know the system is bleed properly so what else could cause the situation I am experiencing? Thanks in advance.